1

Technical aspects
Main catalogue Part 1
Insulation monitoring devices A-ISOMETER®
Insulation fault location system
Bender communication solutions

BENDER Group
Technical aspects affecting the use of
insulation monitoring devices A-ISOMETER®

1. The insulation resistance 2. Power supply systems

In electrical installations and on electrical equipment, the insulation Electrical systems differ on the basis of:
resistance is the determining variable with respect to personal safety, • Current type: AC, DC, 3(N)AC
equipment safety and fire safety. If insulation resistance is insufficient:
• The type and number of live conductors in the system:
• … protection against direct and indirect contact cannot be ensured L1, L2, L3, N resp. L+, L-
• … fault currents will lead to service interruptions • The type of system earthing: IT, TT, TN
• … short-circuit and earth fault currents can cause fires and The type of system earthing must be selected carefully as it essentially
explosions, and damage equipment beyond repair determines the behaviour and properties of the supply system. It
• … malfunctions on electrical equipment can put individuals at risk, is also a contributing factor to issues associated with system usage,
interrupt production or cause systems to come to a standstill such as:
• … high costs can be incurred due to service interruptions, • Supply reliability and/or availability of power
equipment damage or personal injury • Installation outlay
• … the lives of individuals and farm animals are put at risks • Maintenance, downtimes
The insulation resistance on new installations and electrical equip- • Electromagnetic compatibility
ment is usually very good. Over time, operation causes an inevitable
reduction in insulation resistance. Protective measures
The earthing schemes defined in IEC and VDE standards (IT, TN, TT
systems) share a common aim in respect of personal safety, fire
Causes: safety and equipment safety:
Electrical to contain the effects of insulation faults.
• Static overvoltage With respect to personal safety in the event of indirect contact,
• Transient overvoltage they are considered equivalent. However, this is not strictly true of
• Frequency changes the issue of the safety of electrical equipment with relation to:
• Lightning strikes • The availability of power
• Overcurrent • Equipment maintenance
• Voltage waveform Experience shows that a TN-S system (earthed system) or an IT system
(unearthed system) has the best cost/benefit ratio for electrical
Mechanical supply systems.
• Shock, impact
• Kinks, bends
2.1 TT system
• Vibration
In TT systems, one point is connected directly to earth (functional
• Ingress of foreign bodies earthing). The exposed-conductive parts of the electrical installation
Environmental conditions are connected to earth electrodes which are electrically isolated
• Temperature from the earth electrode for earthing the system.
• Moisture Permissible protective devices:
• Chemical influences • Overcurrent protective device
• Pollution, dust deposits, oil • Fault current protective devices (RCDs)
• Aggressive atmospheres
• Ageing of cables and electrical equipment
Other factors
• Animals (e.g. damage caused by rodent)
• Plants
• Improper installations
Different protective measures can be put in place (e.g. defined by
standards) as appropriate for the power supply systems in use, in
order that if the insulation resistance falls below a preset value
this will either be indicated or the current circuit affected will be
disconnected. Figure 2.1: TT system
Where electrical equipment is concerned, regular tests are necessary
at intervals determined by the type of equipment and its conditions
of use.

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 Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®
2.2 TN system
In TN systems, one point is connected directly to earth and the ex-
posed-conductive parts of the electrical installation are connected
to this point via protective earth conductors. There are three types
of TN systems, differentiated on the basis of the arrangement of
the neutral and protective earth conductors:
TN-S The protective earth conductor is separate throughout the
system.
TN-C The neutral and protective earth conductors are combined
in a single conductor throughout the system.
TN-C-S Neutral and protective functions are combined in a single
conductor in a part of the system.
Figure 2.2: TN-S system
Figure 2.3: TN-C system
2.3 IT system
In IT systems, all live conductors are isolated from earth or one point
is connected to earth via an impedance. On the occurrence of an
insulation fault, therefore, only a small leakage current, essentially
caused by system leakage capacitances, can flow. The upstream
fuses do not trip. The voltage supply is also maintained in the
event of single-pole direct earth faults.
The exposed-conductive parts of the electrical installation either
• have separate connections to earth or
• share a common connection to earth or
• share a common connection to the system earth.
The following protective devices are permitted:
• Insulation monitoring devices (IMDs)
• Overcurrent protective devices
• Residual current protective devices (RCDs), also known as
residual current circuit breakers (RCCBs).
Characteristic features
• A first insulation fault will not cause a fuse or RCD/RCCB to trip.
• An insulation monitoring device will detect and signal an imper-
missible deterioration in insulation.
• An insulation fault should be eliminated as quickly as possible
before a second insulation fault can occur on a different live
conductor, as this would cause the system to fail.
Figure 2.4: IT system
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Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®

2.3.1 System leakage capacitances Ce in IT systems 2.3.2 Earthing of loads

The prevailing system leakage capacitance Ce is an important criterion According to IEC 60364-4-441 2007-06, the loads in an IT system
when selecting an insulation monitoring device. The system leakage can be earthed individually or in groups, or they can share a common
capacitance is the total capacitive leakage of all live conductors to connection to earth.
earth. The value of the system leakage capacitance Ce comprises
the cable capacitances Ce of the individual conductors to PE plus
the interference suppression capacitances CL of the electrical
equipment in the loads to earth. Cemax is the value up to which
the insulation monitoring device will operate as intended.

Figure 2.7: All exposed-conductive parts connected to a single

protective earth conductor

Figure 2.5: Capacitance ratings in an IT system

2.3.1.1 Natural system leakage capacitance (A)

The natural system leakage capacitance is the proportion of the
total capacitance Ce ges resulting from the natural (geometrical)
structure of the system's cables to earth. Line capacitances are deter-
mined by the insulation strength between conductors, distance h,
material constant εf, electrical field constant ε0 and area of insulation
between conductors. This value is usually approx. 150 pF/m.
2.3.1.2 Artificial system leakage capacitances (B)
Figure 2.8: Exposed-conductive parts earthed individually or in groups
In order to eliminate EMC faults caused by non-linear loads, differing
frequencies or even high frequency harmonics and meet the require-
ments of EMC standards, loads are wired with interference suppression
capacitances. These filters lead to an increase in system leakage
capacitances and allow higher leakage currents to flow. Radio interfe-
rence suppression capacitors in electronic devices are in the range
10…100 nF.

Figure 2.6: Addition of system leakage capacitances with reference

to the insulation monitoring device

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 Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®

2.4 Comparison of system types

Type of supply system Your benefits Disadvantages

SELV or PELV (safety extra-low voltage • No hazard potential on contact • Limited power if deployment of equipment is to be cost-effective
or protective extra low voltage) • Specific requirements on current circuits

Protective insulation • Maximum level of safety • Double insulation of equipment

• Can be combined with other types of system • Only cost-effective for small loads
• Insulating material pose fire hazard on thermal loads

IT system • EMC friendly • Equipment has to be insulated universally for the voltage
• Increased availability: between external conductors.
1st fault is simply reported • An overvoltage protective device is required for N conductors
Disconnection in the event of a 2nd fault • Potential problems with going offline on second earth fault
• Low earth leakage current in small systems
• Influence on neighbouring installations is reduced,
this in turn makes earthing easier
• Little technical effort for cable and conductor installation
• Use of appropriate devices facilitates fault location

TT system • EMC friendly

• Only compatible with low power ratings due to the use of RCDs
• Protection is dependent on the system's short circuit power
• Regular functional test required
• Little technical effort for cable and conductor installation
• Operational earthing is complex (≤ 2 Ω).
• Touch voltage can vary from one area to another
• Equipotential bonding compulsory for every building
• Can be combined with a TN system

TN-C system • Easy to set up • Not EMC friendly

• Low material expenses • Building stray currents and low frequency magnetic fields
make the system incompatible for use in buildings housing
information technology equipment
• Risk to life and limb in the event of PEN break
• Increased risk of electrical fires

TN-C-S system • A cost-effective compromise for buildings which do not house • Not EMC friendly
information technology equipment. • Low-frequency magnetic fields possible

TN-S system • EMC friendly • Low voltage rise in the healthy phases
• Increased safety engineering outlay for
remote multiple infeeds
• Risk of multiple earthing going unnoticed

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Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®

3. Insulation monitoring devices
According to DIN VDE 0100-410 and IEC 60364-4-41, insulation
monitoring devices are an absolutely essential component of une-
arthed power supplies (IT systems) in order to report a first fault
between a live part and an exposed-conductive part or to earth.
Extract from DIN VDE 0100-410 (translated from the original
German):
An insulation monitoring device shall be provided to indicate the
occurrence of a first fault between an active part and an exposed-
conductive part or to earth, it must trigger an audible or visual si-
gnal.
Note 1: It is recommended to eliminate a first fault with the
shortest practicable delay.
Note 2: An insulation monitoring device may also be required
for reasons not relating to protection against indirect
contact.
Extract from IEC 60364-4-41:
A permanent insulation monitoring device must be designed to
indicate the first occurrence of a live mass or earth fault; it must
trigger an audible or visual signal.
IEC 61557-8 specifies that insulation monitoring devices must
support a prescribed measuring principle that enables them to
monitor both symmetrical and asymmetrical deteriorations in
insulation.
Notes:
• A symmetrical deterioration in insulation can be said to occur
when the insulation resistance of all conductors on the system
to be monitored declines to (approximately) the same extent.
An asymmetrical insulation deterioration in insulation can be
said to occur when the insulation resistance, e.g. of a conductor,
declines to a significantly greater extent than that of the other
conductor(s) in the system.
• Devices known as earth fault monitors, which use the voltage
unbalance (voltage shift) occurring in the event of an earth fault
as a sole measuring criterion, are not insulation monitoring devices
under the terms of this standard.
• Under certain system conditions, a combination of various
measuring techniques, including unbalance monitoring, can be
used for monitoring.
Notes: Symmetrical insulation faults are common on DC voltage
systems and control circuits. If the resistance of both insulation
faults is approximately equal, insulation monitoring devices operating
on the basis of the principle of superimposed voltage measurement
will not be able to detect these insulation faults. It is for this reason
that IEC 61557-8 requires the use of permanent insulation monitoring
devices.

Figure 3.1: Information promoting a pre-emptive response thanks

to insulation monitoring in the IT system.

3.1 Operating principle of an insulation monitoring device

The insulation monitoring device is connected between the live Figure 3.2: Operating principle of an insulation monitoring device
supply conductors and earth and superimposes a measuring voltage
Um. In the event of an insulation fault, the insulation fault RF closes
the measuring circuit between the system and earth, generating a
measuring current Im that is proportional to the insulation fault.
This measuring current generates a corresponding voltage drop at
the measuring resistance Rm, which is evaluated by the electronics.
If this voltage drop exceeds a specific value equivalent to the under-
shooting of a specific insulation resistance, a signal will be output.
IEC 61557-8 specifies detailed requirements to be met by insulation
monitoring devices. Insulation monitoring devices serve as early-
warning systems, providing operators with the information they
need in order to have appropriate maintenance measures taken in
good time.

Figure 3.3: Single-pole (asymmetrical) insulation fault

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 Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®

3.2.3 Summary of measurement methods

There is a direct relationship between the IT system, its structure,
its components and the measurement method of the insulation
monitoring device. Knowing which insulation monitoring device
works with which measurement method is therefore important
from a planning point of view. The table on the next page lists the
measurement methods that can be selected on the basis of system
parameters.

Figure 3.4: Symmetrical insulation fault

3.2 Measurement methods

3.2.1 “Superimposition of measuring DC voltage”
A popular measuring method is to superimpose a measuring DC
voltage between the phase and PE conductor.
This measurement procedure is suitable for monitoring conventional
AC, 3(N)AC systems, e.g. motors. If it is used in AC, 3(N)AC systems
containing galvanically connected DC components, these DC currents
will distort the measurement result. In other words, insulation
faults on the DC side will be signalled with an increased response
sensitivity. The system leakage capacitances Ce prevailing in the
system are simply charged to the measuring voltage and have no Figure 3.5: Selection of measurement methods and system
effect on the measurement following a brief initial response. components

3.2.2 “AMP” measurement method

The AMP measurement method patented for Bender is based on a
special clocked measuring voltage which is controlled by a micro-
controller and adapts automatically to the prevailing system con-
ditions. Software-based evaluation enables system leakage currents
causing interference on the evaluation circuit to be differentiated
from the measured variable proportionate to the insulation resistance
in ohms. This means that broadband interferences such as is typical
of converter operation adversely affect the precise determination
of the insulation resistance.
The AMP Plus measurement method takes interference suppression
to the next dimension. Devices supporting this measurement method
can be used universally in AC, DC and AC/DC systems, e.g. systems
with varying voltages or frequencies, high system leakage capaci-
tances or DC voltage components. This makes them ideal for use
in today's state-of-the-art distribution systems, which are usually
subject to this type of interference (converters, EMC).

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Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®

4. Selecting the right insulation monitoring device 5. Connecting insulation monitoring devices
The following criteria govern the selection of an insulation monitoring 5.1 General
device:
• Nominal voltage?
• AC, DC or AC/DC nominal voltage?
• Main circuit, control circuit or special application?
• System leakage capacitance?
• Response values?
• Expansion to an insulation fault location system?
• Special ambient condictions?

4.1 Type of circuit

4.1.1 Main circuits
Main circuits provide power supply for electrical installations or
buildings. These circuits include equipment for generating, converting,
distributing, switching and consuming of electrical energy.
• A variety of loads on a single system
• Pure AC loads (e.g. motors)
• Loads with electronic components
(e.g. converters, rectifiers, UPS etc.)
• Typical voltage values 690 V, 400 V, 230 V
• High system leakage capacitance due to spatial expansion,
mechanical structure or interference suppression measures
(e.g. battery-powered systems, solar-powered systems).
4.2.2 Control circuits
Control and auxiliary circuits are used for additional functions such
as command input, interlocking, signalling circuits and measuring
circuits. For these circuits, particular emphasis is placed on opera-
tional reliability.
• Spatially restricted, e.g. machine control or emergency lighting
system
• Typical nominal voltages 24, 48, 60, 110, 230 V
• Individual loads or multiple loads of the same type
• Low system leakage capacitance
4.2.3 Special applications
Circuits for which special standards or requirements have been
defined.
• Mobile power generators
• Hospitals
• MV converter drives
Figure 5.1: Connections on an insulation monitoring device
Connection to the live conductors on the IT system
Most Bender insulation monitoring devices feature connection
monitoring. to monitor the connection between terminals. (e.g. L1
and L2). A break in the loop will be signalled. For this function, the
insulation monitoring device must be connected to the system to
be monitored with two separate lines.
Note: Connection to the same phase or N is permitted.
Connection to the power supply
The supply voltage can be taken either from the system being
monitored or, for example, from a control voltage system.
Connection to an external kΩ measuring instrument
When connecting an external measuring instrument, make sure
that the centre scale mark on the measuring instrument and the
internal resistance of the insulation monitoring device are identical
(e.g. 120 kΩ).
Connection to an RS-485 interface
To link e.g. to a building services control system/process control
system or exchange data with other Bender systems capable of
communication.
Alarm contacts
On some insulation monitoring devices, the functional principle of
the alarm relays can be configured. When the relay is set to N/C
operation, the relay is energised. This means that the failure of the
supply voltage can be signalled by the relay dropping out (fail-safe
response).
Connection to earth
The connection to earth is made via two separate lines E/KE. This
connection enables the correct function of the connection to be
monitored and interruptions to be signalled.
Connection of the test button
Test of the device function.
Connection of the reset button
To reset the fault memory.

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 Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®
5.2 Connection to a disconnected IT system
When monitoring a disconnected IT system, make sure that the
measuring voltage of the insulation monitoring device can be
superimposed on all live conductors. This is achieved either via
the load: (Note: The windings on a motor/transformer are low
resistance for the measuring voltage).
Figure 5.2: Superimposition of measuring voltage,
e.g. by motor windings
5.3 Monitoring of an IT system with multiple
infeeds
In an IT system, only one insulation monitoring device may be active
at any one time, otherwise, the measuring voltages will generate
mutual interference and the measurement results will be distorted.
If two IT systems are working independently of one another, there
must be an insulation monitoring device installed in each system.
However, it must be ensured that if the two systems are coupled,
only one of these devices can ever be active at any one time.
* Bender-specific system bus
Figure 5.3: Insulation monitoring in two IT systems
which can be interconnected
Figure 5.4: Connection to the supply voltage
Fuse protection for insulation monitoring devices
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Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®

5.4 Fuse protection for insulation monitoring devices Note:

Most insulation monitoring devices are connected to the system An insulation monitoring device will signal a drop in insulation
to be monitored via two connecting wires. resistance without an “actual” insulation fault being present. This
In principle, any type of fuse protection for an insulation monito- can be due, for example, to moisture (if the installation has been
ring device must be considered as line protection. According to out of service for a long period of time). Once the installation has
IEC 60364-4-43, fuse protection is always required if the current been put back into operation, the insulation resistance usually in-
carrying capacity is reduced by a decrease in cable cross section, a creases automatically due to the moisture disappearing as the
change in cable installation method, a change in conductor insu- operating temperature is reached.
lation or a change in the number of conductors. Protective devices The values listed in the table below are recommended minimum
for overload protection can be omitted from lines and cables in values. IEC 60364-5-53 contains practical instructions regarding
which overload currents will not occur as long as they feature no the selection of response values for insulation monitoring devices.
taps or plug-and-socket devices. It can generally be assumed that A value of 50 Ω/V of system voltage is used as a guide value.
these conditions can be met both where the power supply connection The response values listed in the table below have been taken
is concerned and in respect of the supply voltage connection on from the corresponding standards.
insulation monitoring devices. The situation as regards short-circuit
protection is very different. The supply voltage terminals must be
fitted with overcurrent releases for short-circuit protection.
We recommend the use of 6 A fuses. Fuse protection also makes it
easier to access devices for service operation. Protective devices for
short-circuit protection do not have to be used for the power supply
connection if the risk of a short-circuit is minimal (see IEC 60364-4-43).
Therefore, we recommend at least one cable installation protected
against short-circuits and earth faults. Reducing the risk of short-
circuits to a minimum and deciding whether this has been achieved
is often very difficult. In cases of doubt, we recommend installing
protective devices for short-circuit protection in the power supply
coupling in the form of 6 A fuses. On devices with built-in connection
monitoring, the blowing of a fuse is signalled as an open circuit.
5.5 Setting of the response values
When operating an insulation monitoring device, make sure that
the total insulation resistance of the relevant IT system is measured.
This total resistance is calculated by adding together the resistive
leakage of all outgoing lines connected in parallel to earth.
The response value of the insulation monitoring device should be
set to approx. 100 Ω/V.
Example: System voltage 500 V
A-ISOMETER® IRDH275
set to 50 kΩ
If an insulation monitoring device is being used in an existing
complex installation, we recommend setting the response value
to approx. 50 Ω/V.

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 Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®

Required insulation values and recommended response values of insulation monitoring devices (IMDs)

Required insulation Recommended response

Standard Application Nominal voltage resistance value of the IMD
IEC 60364-5-53 Annex H Selection and erection of electrical 230 V pre-warning 34.5 kΩ
equipment – Isolation, switching 100 Ω/V=23 kΩ
and control warning
50 Ω/V=11.5 kΩ 17.25 kΩ

IEC 60364-7-710 Medical locations 230 V 50 kΩ 75 kΩ

UL 2231-2 Supply Circuits for electric vehicles 100 Ω/V at nominal voltages

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Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®

5.5.1 Response values control circuit
If, in accordance with DIN VDE 0660 and DIN VDE 0435 Un is taken
as the minimum withstand voltage (0.1…0.15) for an actuating
element integrated in the control, disregarding coil impedance, a
resistor ZH connected in series which is able to prevent tripping at
5% overvoltage can be dimensioned as follows:
5.6 Expansion of the nominal voltage range
AGH coupling devices can be used to expand the nominal range of
an insulation monitoring device. These modules are connected
between the insulation monitoring device and the system to be
monitored.

ZH ≈ (10.5…7) Un2
PH
PH = Rated apparent withstand power of the actuating element.
This formula can be used to calculate the following recommended
response values for the insulation monitoring device in control
circuits (values in Ω):
1 VA 5 VA 10 VA 30 VA 50 VA
24 V 6048 Ω 1210 Ω 605 Ω 202 Ω 121 Ω
48 V 24192 Ω 4838 Ω 2419 Ω 806 Ω 484 Ω
60 V 37800 Ω 7560 Ω 3780 Ω 1260 Ω 756 Ω
110 V 127050 Ω 25410 Ω 12705 Ω 4235 Ω 2541 Ω
220 V 508200 Ω 101640 Ω 50820 Ω 16940 Ω 10164 Ω
230 V 555450 Ω 111090 Ω 55545 Ω 18515 Ω 11109 Ω
Figure 5.7: Expanding the nominal voltage range of an insulation
monitoring device

Figure 5.6: Response values insulation control circuit

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6. Examples of application
6.1 Monitoring of a main circuit

Figure 6.1: Insulation monitoring in a main circuit with

a pure AC load Figure 6.3: Monitoring of an AC control circuit

Figure 6.2: Main circuit with variable-speed drive

Figure 6.4: Monitoring of a DC control circuit
6.2 Monitoring of a control circuit
IEC 60204-1 specifies that earth faults in control circuits should not
induce accidental starting or potentially dangerous motion of a
machine; neither should they prevent a machine stopping. In general,
control circuits are supplied with power via a safety transformer
with separate windings or a safely isolated power supply, whereby
the secondary voltage must not exceed 50 V. The control circuit
itself may be operated either as an earthed system (TN system) or
an unearthed system (IT system). However, if high resistance insu-
lation faults go undetected on sensitive components in a control
circuit in particular, this can lead to control errors. In an earthed
system, these faults are not detected by a fuse, as the fault current
is too low to blow a fuse. If the insulation fault is low-resistance
fault, the fuse will blow and the installation will be brought to a
standstill. In order to avoid this, control circuits are operated without
earthing and monitored with an insulation monitoring device.

Figure 6.5: Monitoring of an AC/DC control circuit

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Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®
6.3 Monitoring a disconnected load
Many loads are only switched on in an “emergency” (e.g. fire
pumps, slides, all types of heating, etc.). Whilst they are offline,
however, moisture or other factors can cause insulation faults in
the associated supply cable or on the load itself. When these loads
are switched on, the protective device will respond or fires will
start, thereby preventing operation.
The insulation monitoring device, also known as the offline moni-
tor, monitors the insulation resistance during offline periods and
signals insulation faults immediately. When the load is switched
on, insulation measurement based on the K contactor is deactiva-
ted. The fault memory is also able to detect transient insulation
faults. If it can be assured that all poles on the load will be taken
offline, this monitoring can also be used in TN and/or TT systems.
Response value of the insulation monitoring device:
The insulation monitoring device must signal insulation faults ≤ 1 MΩ,
this is because motors are frequently rendered non-operational at
an insulation resistance of ≤ 500 kΩ.
Figure 6.6: Monitoring an offline motor
14 Technical aspects – Main catalogue Part 1
6.4 Monitoring of mobile generators
Electrical safety is often difficult to assure on mobile power gene-
rators.
• In very few cases does the ground/environment permit an
earthing system to be installed (stones, rubble, rock, asphalt, etc.
would have to be penetrated).
• Time is of the essence, there is not enough time to measure and
check the protective measure.
• The relevant skilled person is lacking.
However, the ability to respond immediately and appropriately
is vital in an emergency situation. It is for this reason that mobile
power generators feature the protective measure (Protection by
electrical separation with insulation monitoring and disconnection)
in accordance with IEC 60364-5-51.
Figure 6.7: Mobile power generator with the protective measure
“Protection by electrical separation with insulation
monitoring and disconnection”
 Technical aspects affecting the use of insulation monitoring devices A-ISOMETER®

6.5 Monitoring medical llocations

IEC 60364-7-710 specifies that all Group 2 rooms in medical locations must be fitted with an IT system supporting insulation monitoring
as well as load and temperature monitoring. A central facility for the display of status messages and alarms must also be provided.

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Technical issues affecting the use of insulation fault location systems

1. Installation safety and availability 3. Why use insulation fault location?

Today's industrial, power generation and distribution installations Essentially, insulation fault location is necessary for three technical
are complex structures characterised by sophisticated controls reasons:
and high productivity. This is precisely why failures can incur huge
1. Protection against electric shock
costs. Thanks to the latest technical innovations, however, optimum
(e.g. in a 3(N)AC 400 V system)
provision for installation safety can now be made as early as the
IEC 60364-4-410 (DIN VDE 0100-410):recommends eliminating
planning stage, ongoing operation can be permanently monitored
the first insulation fault with the shortest practicable delay. The
and defective installation components can be detected quickly
occurrence of a second fault will introduce the risk of electric
and reliably.
shock, at which point the installation would have to be discon-
2. Unearthed power supplies nected. The order of magnitude for insulation fault monitoring
here ranges from 5…10 kΩ.
Unearthed power supplies (IT systems) have an invaluable advantage
in that a first fault will not induce a failure. This means that complex 2. Avoidance of fire risks
processes and production sequences will not be interrupted unex- (e.g. in a 3(N)AC 400 V system)
pectedly. What actually happens is quite the opposite: IT systems A fault current generating excess heat rise at the fault location
can continue to operate under controlled conditions and faults can can flow in the event of undetected high-resistance insulation
be rectified at a later stage, without incurring the costs associated faults. There is an acute fire risk even at powers of ≥ 60 W. The
with failures. order of magnitude for insulation fault monitoring here is in
The A-ISOMETER® insulation monitoring device provides the basis the range of 1 kΩ.
for this mechanism. It monitors the insulation resistance of the 3. Avoidance of control errors
IT system to earth and outputs a signal accordingly should a specific (e.g. in a DC 220 V system)
value be exceeded. This pre-emptive information can then be In electrical installations, the smallest fault currents can cause
used to determine the appropriate time for insulation fault location, PLCs or contactor controls to respond incorrectly. This exposes
e.g. in the event of disconnection for revision purposes. However, individuals to an increased risk of injury, e.g. on press controls
the devil is in the detail. In particular where complex installations or in the event of uncontrolled machine motions. The order of
and power supplies whose circuits are distributed across a wide magnitude for insulation fault monitoring here ranges from
area are concerned, insulation fault location can be a costly activity 10…15 kΩ.
in terms of both time and personnel resources.
EDS insulation fault location systems can provide a solution to this
problem. These systems locate insulation faults automatically during
operation and indicate the faulty outgoing circuit via an LCD or
other type of visualisation unit. Operators benefit as follows:
• Installations do not have to be disconnected –
Insulation fault location is automatic during operation.
• Fault locations are identified and displayed precisely –
this saves time and resources.
• Modular system concept –
The system is optimised for the installation and can be set up in
accordance with the requirements of the operator.

Figure 3.1: Potential for reducing costs when using EDS systems

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 Technical issues affecting the use of insulation fault location systems

4. How does an insulation fault location system work?

An insulation fault location system comprises an insulation fault
test device and an insulation fault evaluator connected to one or
more measuring current transformers. The A-ISOMETER® of the
IRDH575 series features a built-in insulation fault test device.
Functional sequence:
• Start insulation fault location by activating the insulation fault
test device.A-ISOMETER®.
• The insulation fault test device briefly connects the live conductors
to earth.
• Electronic current limiting, this connection and the insulation
fault create a closed circuit, in which a test current IT idetermined
by the system voltage flows. The test current is limited to a
maximum value.
• The test current pulse flows from the insulation fault test device Figure 4.1: Operating principle of insulation fault location
via the live conductors, the insulation fault Rf and the earth wire
(PE conductor) and back to the insulation fault test device.
• The test current signal is detected by all measuring current
transformers on the circuit and evaluated by EDS insulation fault
evaluators.
• The fault location can be identified using the assignment between
measuring current transformers and circuit.

Figure 4.2: Characteristic of test current IT EDS system

Figure 4.3: Test current pulse cycle on the EDS system

Technical aspects – Main catalogue Part 1 17

Technical issues affecting the use of insulation fault location systems

5. Definitions for the insulation fault location system

IRDH575 Insulation monitoring device
with built-in insulation fault test
device
EDS4… Insulation fault evaluator
W… Measuring current transformers
IT Test current
RF-V Insulation fault upstream of
measuring current transformer
Ce-V System leakage capacitance
upstream of measuring current
transformer
RF-N Insulation fault downstream of
measuring current transformer
Ce-N System leakage capacitance
downstream of measuring current
transformer

Bild 5.1 Definitions for insulation fault location

6. Variants of insulation fault location

There are essentially three different types of insulation fault location:
• Automatic insulation fault location/stationary systems
• Manual insulation fault location/portable systems
• Main circuit or control circuit application
6.1 Automatic insulation fault location/permanently installed
systems
The insulation monitoring device with built-in insulation fault test
device, the insulation fault evaluator and the associated measuring
current transformers are components of the installation.
Insulation fault location is started automatically by the insulation
monitoring device.

Figure 6.1: Automatic insulation fault location

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 Technical issues affecting the use of insulation fault location systems

Figure 6.2: How an automatic EDS insulation fault location system might be implemented

MK800

Figure 6.3: How an EDS automatic insulation fault location system with central administration via Etheernet/Internet might be implemented

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Technical issues affecting the use of insulation fault location systems

Figure 6.4: How an automatic EDS insulation fault location system might be implemented in coupled DC systems

Figure 6.5: How an automatic EDS insulation fault location system might be implemented in two coupled IT systems

20 Technical aspects – Main catalogue Part 1

 Technical issues affecting the use of insulation fault location systems

Figure 6.6: Application on an intensive care unit in medical locations

Technical aspects – Main catalogue Part 1 21

Technical issues affecting the use of insulation fault location systems

6.2 Manual insulation fault location/portable systems

Manual insulation fault location can be implemented to meet the
following requirements:
a) In addition to permanently installed EDS systems, a portable c) If the IT system has been deenergised, a portable insulation
insulation fault evaluator is used for insulation fault location in fault test device with built-in measuring voltage source is used.
secondary outgoing circuits.
b) If the installation does not have an insulation fault test device, a
portable insulation fault test device is used.

Figure 6.7: Manual insulation fault location with permanently Figure 6.8: Manual insulation fault location in IT systems without
installed EDS systems insulation fault test device

Note for Figure 6.9:

IT system offline, i.e. the test current is
generated by the portable insulation fault
test device (PGH186) if the device is also
suitable for use in earthed systems (TN, TT
systems), if all poles are offline and there is
no direct connection between the system
PGH186
and earth.

Figure 6.9: Manual insulation fault location with portable insulation fault test device in
disconnected IT systems (no system voltage)

22 Technical aspects – Main catalogue Part 1

 Technical issues affecting the use of insulation fault location systems

6.3 Distinguishing features of main circuit/control circuit

The essential difference in the two applications is in the significantly reduced test current for application in control circuits and/or the response
sensitivity.
6.3.1 EDS systems for main circuits
Characteristics of main circuits
• Nominal system voltage Un up to 690 V
• Wide spatial distribution, system leakage
capacitance up to 20,000 μFV (product of
system leakage capacitance and nominal
system voltage, e.g. 400 V x 50 μF =
20,000 μFV)
• High residual currents up to max. AC 10 A
• Loads causing interferences
(e.g. converters, inverters, etc.)

Figure 6.10: EDS in the main circuit

6.3.2 EDS systems control circuits

Characteristics of control circuits
• Nominal system voltage Un up to 230 V
• Restricted spatial distribution, system
leakage capacitance up to 300 μFV
(product of system leakage capacitance
and nominal system voltage
e.g. 24 V x 10 μF = 240 μFV)
• Low residual currents up to max. AC 1 A
• No loads causing interferences

Figure 6.11: EDS in the control circuit

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Technical issues affecting the use of insulation fault location systems

6.3.4 EDS systems with switching function

Characteristics of switching function:
• All measuring channels are scanned in
parallel during insulation fault location.
• The max. scanning time is ≤ 10 s.
• At the end of this time the relay contact
switches the faulty measuring channel
concerned.
• This switching contact can be used to
disconnect the faulty outgoing circuit via
a contact element.

Figure 6.12: EDS in the control or main circuit with switching function

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 Technical issues affecting the use of insulation fault location systems

7. Device selection
7.1 Device selection table for permanently installed systems:
Type of supply system AC, DC, AC / DC (mixed systems) AC, DC, AC / DC (mixed systems)
Application Main circuit Control circuit
Function Insulation monitoring device A-ISOMETER® / insulation fault test device
Type IRDH575 IRDH575

Nominal system voltage Un (B1) 3AC / AC 20…575 V 3AC/AC 20…150 V / DC 20…150 V

(version IRDH575B1-4227, RDH575B1-4235)
Nominal system voltage Un (B2) 3AC / AC 340…760 V DC 340…575 V --
Supply voltage
IRDH575B1-435 AC 88…264 V AC 88…264 V
IRDH575B2-435 DC 77…286 V DC 77…286 V
IRDH575B1-4235 -- --
IRDH575B1-427 DC 19.2…72 V DC 19.2…72 V
IRDH575B1W-4227 -- --
Test current 10 / 25 / 50 mA 1 / 2.5 mA
Response values 1 kΩ…10 MΩ 1 kΩ…10 MΩ
LC display 4 x 20 characters 4 x 20 characters
Alarm relay 3 changeover contacts 3 changeover contacts
Interface / protocol RS-485 (BMS) RS-485 (BMS)
Address range 1…30 1…30

Insulation fault evaluators

Type EDS460-D/DG… EDS490-D… EDS460-L… EDS490-L… EDS461-D… EDS491-D… EDS461-L… EDS491-L…

Graphic LCD × × -- -- × × -- --
7-segment / LED display -- -- × × -- -- × ×
US: DC 16…94 V, EDS460-D-1, EDS490-D-1 EDS460-L-1 EDS490-L-1 EDS461-D-1 EDS491-D-1 EDS461-L-1 EDS491-L-1
AC 42…460 Hz 16…72 V EDS460-DG-*
US: AC / DC 70…276 V EDS460-D/DG-2, EDS490-D-2 EDS460-L-2 EDS490-L-2 EDS461-D-2 EDS491-D-2 EDS461-L-2 EDS491-L-2
AC 42…460 Hz EDS460-DG-2*
Scanning time < 10 s for up to 1080 measuring channels < 10 s for up to 1080 measuring channels
Response value 2…10 mA 0,2…1 mA
Residual current display 100 mA...10 A (EDS460DG 20mA-2 A) 10 mA … 1 A
Parameterization function × × -- -- × × -- --
Error codes display × × × × × × × ×
Address range 1…90 1…90 1…90 1…90
Internal clock (RTC) × × -- -- × × -- --
History memory × × -- -- × × -- --
Alarm relay “Common alarm” 2 x 1 changeover contact 2 x 1 changeover contact
Alarm relay per channel -- 12 x 1 N/O contact -- 12 x 1 N/O contact -- 12 x 1 N/O contact -- 12 x 1 N/O contact
* EDS460-DG-…particularly for localising insulation faults in DC IT systems with a number of branch circuits where high system leakage capacitances are involved

EDS460-D/DG… EDS490-D… EDS460-L… EDS490-L…

Technical aspects – Main catalogue Part 1 25

Technical issues affecting the use of insulation fault location systems

Type of supply system AC, DC, AC/DC (mixed systems) AC, DC, AC/DC (mixed systems)
Application Main circuit Control circuit
Function Measuring current transformers
Dimensions Type Dimensions Type
W… series

Circular ø 10 W10 ø 10 W10-8000

ø 20 W20 ø 20 W20-8000
ø 35 W35 ø 35 W35-8000
ø 60 W60 ø 60 W60-8000
ø 120 W120
ø 210 W210
W…-S… series

Circular ø 20 W0-S20
ø 35 W1-S35 ø 35 W1-S35-8000
ø 70 W2-S70
ø 105 W3-S105
ø 140 W4-S140
ø 210 W5-S210
WR… series

Rectangular (H x W) 70 x 175 WR70x175

115 x 305 WR115x305
WR…S series

Rectangular (H x W) 70 x 175 WR70x175S

115 x 305 WR115x305S
150 x 350 WR150x350S
200 x 500 WR200x500S

26 Technical aspects – Main catalogue Part 1

 Technical issues affecting the use of insulation fault location systems

Type of supply system AC, DC, AC/DC (mixed systems) AC, DC, AC/DC (mixed systems)
Application Main circuit Control circuit
Function Measuring current transformers
Dimensions Type Dimensions Type
WS… series

Split-core (W x H) 20 x 30 WS20x30 20 x 30 WS20x30-8000

50 x 80 WS50x80 50 x 80 WS50x80-8000
80 x 120 WS80x120
WS…S series

Split-core (W x H) -- -- 20 x 30 WS20x30S-8000
50 x 80 WS50x80S 50 x 80 WS50x80S-8000
80 x 80 WS80x80S
80 x 120 WS80x120S
80 x 160 WS80x160S

Technical aspects – Main catalogue Part 1 27

Technical issues affecting the use of insulation fault location systems

7.2 Device selection table for portable systems with a test device (A-ISOMETER® IRDH575) installed

Type of supply system AC, DC, AC / DC (mixed systems) AC, DC, AC / DC (mixed systems)
Application Main circuit Control circuit
Function Insulation monitoring device A-ISOMETER® / insulation fault test device
Type IRDH575 IRDH575

Nominal system voltage Un (B1) 3AC / AC 20…575 V 3AC/AC 20…150 V / DC 20…150 V

DC 20…575 V (version IRDH575B1-4227, RDH575B1-4235)
Nominal system voltage Un (B2) 3AC / AC 340…760 V DC 340…575 V --
Supply voltage
IRDH575B1-435 AC 88…264 V AC 88…264 V
IRDH575B2-435 DC 77…286 V DC 77…286 V
IRDH575B1-4235 -- --
IRDH575B1-427 DC 19.2…72 V DC 19.2…72 V
IRDH575B1W-4227 -- --
Test current 10 / 25 / 50 mA 1 / 2.5 mA
Response values 1 kΩ…10 MΩ 1 kΩ…10 MΩ
LC display 4 x 20 characters 4 x 20 characters
Alarm relay 3 changeover contacts 3 changeover contacts
Interface / protocol RS-485 (BMS) RS-485 (BMS)
Address range 1…30 1…30

Insulation fault evaluators

Type EDS190P

LCdisplay ×
Test current max. 1/2,5/10/25/50 mA
Response value 0.2…1/2…10 mA
Supply voltage DC 6 V +/- 10%, external battery charger
Measuring clamps
20 mm PSA3020 PSA3320
52 mm PSA3052 PSA3352
115 mm PSA3165 --

Complete system EDS3090 EDS3091

Comprising Aluminium case, EDS190P, PSA3020, PSA3052, battery charger Aluminium case, EDS190P, PSA3020, PSA3052, battery charger

28 Technical aspects – Main catalogue Part 1

 Technical issues affecting the use of insulation fault location systems

7.3 Device selection table for portable systems without a test device installed
Application Main circuit Control circuit
in operation offline
Function Insulation fault test device PGH
Type PGH185, PGH186 PGH185

Nominal system voltage Un 3AC/AC 42…460 Hz 20…575 V 3AC/AC 42…460 Hz 20…575 V 3AC/AC 42…460 Hz 20…265 V
DC 20…504 V DC 20…504 V DC 20…308 V
US AC 230 V PGH185 PGH186 PGH183
US AC 90…132 V PGH185-13 -- PGH183-13
Test current 10/25 mA 10/25 mA 1/2.5 mA

Insulation fault evaluators

Type EDS190P

LC display ×
Test current max. 1/2,5/10/25/50 mA
Response value 0.2…1/2…10 mA
Supply voltage DC 6 V +/- 10%, external battery charger
Measuring clamps
20 mm PSA3020 PSA3320
52 mm PSA3052 PSA3352
115 mm PSA3165 --
Complete system EDS3090 EDS3091
Type EDS3090PG, EDS3096PG for US = AC 50…60 Hz 230 V EDS3091PGH for US = AC 50…60 Hz 230 V
EDS3090PG-13, EDS3096PG-13 for US = AC 50…60 Hz 90…132 V EDS3091-13 for US = AC 50…60 Hz 90…132 V
Comprising Aluminium case, PGH185, Aluminium case, PGH186, Aluminium case, PGH185-3,
EDS190P, PSA3020, PSA3052, EDS190P, PSA3020, PSA3052, EDS190P, PSA3020, PSA3052,
battery charger battery charger battery charger

Technical aspects – Main catalogue Part 1 29

Technical issues affecting the use of insulation fault location systems

8. Insulation fault location in practice
The following currents flow through the measuring current
transformers on EDS insulation fault evaluators:
• The test current IT generated by the insulation fault RF-N.
• Residual currents IΔn flowing through the system leakage
capacitances CE-V and CE-N and/or generated by RF-V and RF-N.
• Transient leakage currents generated by switching and control
activities in the system.
• Low-frequency leakage currents generated by the use of
converters.
8.1 Requirements for reliable insulation fault location
The insulation fault evaluator is charged with locating the insulation
fault downstream of the measuring current transformer RF-N. It is
designed to recognise reliably the test current caused by the insu-
lation fault for this purpose. Requirements:
• Main circuits: Test current IT = 2…50 mA.
• Control circuits: Test current IT = 0.2…5 mA.
• The upstream capacitances CE-V must be at least as large as the
downstream capacitances CE-N.
• The insulation fault must be present for at least 30 seconds.
• There must not be any connections to other sub-distributions
downstream a measuring current transformer.
• The total system leakage capacitance must not exceed specific
values:
- Main circuits up to 30.000 uFV (product of the system leakage
capacitance and nominal system voltage).
- Main circuits up to 1.000 uFV (product of the system leakage
capacitance and nominal system voltage).
• The sum of the test current and residual current flowing
through the measuring current transformer must not exceed
the following values:
- maximum 10 A for main circuits
- maximum 1 A for control circuits
• Not only does the value of the residual current influence the
reliable detection of the test current but also the respective
frequency of the residual current. Residual currents deviating
from the system frequency may be caused by the use of frequency
converters, for example. The behaviour of the EDS is as follows:
- When residual currents ≥ system frequency (50/60/400 Hz) occur
exceeding 10 A in main circuits resp. 1 A in control circuits, an
alarm message is generated via alarm 1.
- When residual currents ≤ system frequency (50/60/400 Hz) occur,
exceeding the characteristics represented in the ault curve,
the message “peak” or the message “fault” is generated. This
message appears on the display.
See the fault curve below in this context.
Example: When a residual current of 2 A with a frequency of 20
Hz occurs, (dot in the diagram), the message “peak” or “fault”
appears on the display.

Alarm message
EDS461/491

EDS460/490

1 10
Residual current

0,9 9

0,8 8

0,7 7

0,6 6

0,5 5

0,4 4 Message “peak” - Permissible range -

Insulation fault location not possible Insulation fault
0,3 3 location possible

0,2 2

0,1 1

0
1 5 10 50 100 400

Frequency (Hz)

A feature…

30 Technical aspects – Main catalogue Part 1

 Technical issues affecting the use of insulation fault location systems

9. Planning check list for EDS systems

9.1 How should insulation fault location be implemented?
a) Permanently installed system See chapter 1.7
b) Portable system for occasional fault location See chapter 1.7

9.2 Information about the IT system to be monitored

a) IT system AC, 3(N)AC, DC Note the technical data of the insulation monitoring device and
fault curve
b) System voltage, system frequency Note the technical data of the insulation monitoring device and
fault curve
c) Main circuit, control circuit Note the information about device selection (chapter 7)!
d) Maximum system leakage capacitance Note the limit values in chapters 6.3.1/6.3.2
e) Maximum residual currents Note limit values 10 A/1 A; calculate by means of measurement if
necessary

9.3 Information about the load structure

a) Are you using loads such as frequency converters, power
converters, rectifiers, PLCs, interference suppression filters
or diode-decoupled DC loads?
b) Are your applications in the medical sector or do they in-
volve diode-decoupled DC IT systems?
Note the technical data of the insulation monitoring device and
fault curve (chapter 8)
Note the information about device selection/circuit design!

9.4 Outgoing circuits to be monitored

a) How many outgoing circuits are to be monitored? Calculate the corresponding number of measuring current transformers
b) Busbar dimensions Note the information about device selection/circuit design (chapter 7)
c) Cable diameters Define type for measuring current transformer
d) Cable bundle dimensions Define type for measuring current transformer
e) Do the outgoing circuits need to be isolated? If not, split-core WS… series measuring current transfomers must
be used

9.5 Required communication options:

a) Visual and audible signals Device selection in chapter 1.8
b) Location of operator panel installation Device selection in chapter 1.8
c) Interface with building services control system/process Device selection in chapter 1.8
control system
d) Interface with TCP/IP Device selection in chapter 1.8
e) Interface with PROFIBUS-DP Device selection in chapter 1.8
f) Interface with Jbus/Modbus Device selection in chapter 1.8
g) Visualization Device selection in chapter 1.8
h) Information via telephone/e-Mail/mobile phone/Internet Device selection in chapter 1.8

9.6 Maintenance concept: Who does what?

a) Coordination of measures: Agree between employees
b) Who is to parameterize the insulation fault location system Agree between employees
and evaluate alarms?
c) When can insulation faults be rectified? Draw up schedule
d) How are insulation faults to be rectified? Specify procedure
e) Where are the loads on the outgoing circuits to be moni- Provide appropriate installation documentation
tored located?

Technical aspects – Main catalogue Part 1 31

The technical aspects when using Bender communication solutions
Modern communication
Due to the fact that increasing demands are placed on communica-
tion capability, data transparency and flexibility, the use of modern
fieldbus and network technologies has become a must. Hence,
operating, warning and fault messages via the Web or the network,
for example, substantially contribute to increasing the transparency
of power supply systems, and also allow a fast reaction to critical
operating states. In addition, important messages can be transfer-
red via short message service or e-mails to mobile phones or lap-
tops of the service personnel. Early information about location and
the cause of fault allow time and cost-efficient deployment of ser-
vice personnel and can avoid equipment failure or the damage of
expensive devices.
Communication structure of Bender systems at a glance
32 Technical aspects – Main catalogue Part 1
Electrical Safety Management
Embraced by the term “Electrical Safety management” Bender
provides coherent solutions for the electrical safety of power sup-
plies in all areas. Carefully matched products and systems with in-
novative measuring techniques, communication solutions for the
visualisation of data from Bender monitoring systems as well as
easy connection to fieldbus systems and to Building Control and
Central Building Process Control Systems provide the maximum
possible safety, economic efficiency and transparency. The whole
product range is completed by comprehensive service starting
from expert advice through the whole life cycle of the products.
 The technical aspects when using Bender communication solutions

Communication possibilities with Bender systems and devices

1 - Bender systems or devices with BMS bus, e.g. RCMS, EDS, 10 - PC with standard browser (Internet Explorer, Firefox, Opera, .etc.)
MEDICS® systems, A-ISOMETER®s IRDH275, 375, 575 11 - OPC server in FTC470XET
2 - Bender BMS bus (internal) 12 - OPC client: Axeda Wizcon visualisation software
3 - Alarm indicator and test combination MK2430 13 - OPC client: Touch Panel TPC
4 - Alarm indicator and test combination MK800 14 - OPC client: Scada software
5 - TM alarm indicator and operator panels 15 - FTC470XET functionality: E-mail notification via Internet
6 - Protocol converter FTC470XDP 16 - FTC470XET functionality:
Conversion BMS bus/PROFIBUS DP Operation of Bender systems via web browser
7 - Protocol converter FTC470XMB 17 - FTC470XET functionality:
Conversion BMS bus/Modbus RTU Short message service to mobile phones
8 - Bender BMS bus (external) 18 - BMS OPC server
9 - Protocol converter FTC470XET 19 - PC with software BMS OPC server
Conversion BMS bus/Ethernet (TCP/IP), web server,
20 - Protocol converter DI-2USB BMS bus (RS-485)/USB
OPC interface

15 16 17

12 13 14

10
11

9 19
20
18

1 3 8

6 7

PROFIBUS DP Modbus RTU

4 5

Technical aspects – Main catalogue Part 1 33

The technical aspects when using Bender communication solutions
1. BMS bus
The BMS bus (Bender Measuring Device Interface) is Bender's own
development and enables optimum data exchange between all
communication-capable Bender products. The BMS bus is an RS-485
interface utilising a protocol especially developed for Bender devices.
Function – Master-Slave principle
The BMS bus operates according to the Master-Slave principle.
That means, that one device operates as the master and all other
devices function as slaves. Hence, only one master may exist on
each BMS bus. The master requests all devices on the bus on a cyclic
basis, listens to their signals and carries out the respective commands.
During operation the master function can temporarily be taken
over by a slave. Every device on the BMS bus must be assigned its
own unique address. Address 1 is assigned to the master.
Internal and external bus
Several BMS bus systems can be interconnected to one common
system. For this purpose, one PRC1470 control and indication panel
or one TM operator panel is required for each of the systems.
Several PRC1470 or TM operator panels communicate with each
other via the external bus. A consecutive address must be assigned
to each device. The master function is passed sequentially according
to the passing-token principle. That means, the master function is
passed sequentially to each PRC1470 or TM operator panel so that
only one station may talk at a time. On the internal bus each TM
operator panel communicates with devices of the associated BMS
system. The respective device is the master with address 1 assigned
to it.
Cables and cable lengths (internal and external BMS bus)
The specification of the RS-485 interface limits the maximum
length of the interface to 1200 m. With longer cables, additional
measures are necessary (installation of a DI-1 repeater). The inter-
face cable should be a shielded cable. A suitable cable type is, for
example, J-Y(ST)Y 2 x 0.6. If interface cables are implemented as
spur cables, the maximum length is limited to 1 m. If longer spur
cables are used, safe communication cannot be guaranteed. The
number of devices on a bus must not exceed 32. By using repeaters
(e.g. Bender DI-1) another 32 devices can be connected or the cable
length can be extended by another 1200 m.
Terminating resistors (internal and external BMS bus)
The BMS bus must be terminated at both ends with terminating
resistors of 120 Ω (0.25 W). The resistances are to be connected in
parallel to the terminals A and B. A BMS bus not being terminated
may become unstable and may cause malfunctions.
34 Technical aspects – Main catalogue Part 1
The BMS bus cyclically transmits alarm and status indications.
In addition, the protocol contains commands for scanning and
modifying device parameters as well as various control commands.
Basic rules for the design of a BMS bus
1. Every BMS bus must be controlled by a master.
2. Only one master may exist in each BMS bus system.
3. Every device on the BMS bus must be assigned its own unique
address.
4. Never assign one address twice.
5. The BMS bus must be terminated at both ends with terminating
resistors of 120 Ω.
6. The cable length must not exceed 1200 m, but can be extended
by a DI-1 repeater.
7. The number of devices on a BMS bus must not exceed 32, but
the bus reach can be extended by DI-1 repeaters (DI-2 or DI-3).
8. The BMS bus must provide a favourable topology (without
branch circuits).
9. The bus cable (J-Y(ST)Y 2 x 0.6) must be shielded and earthed
at one side.
10. Take care not to mix up bus terminal A and B.
Addresses and address ranges
Every device on the BMS bus must be assigned its own unique
address. Address 1 is assigned to the master. Address 000 is the
“broadcast address” which addresses all other nodes and may
therefore not be assigned to any other device. 150 of 255 addresses
theoretically available (1 byte address, also 28 = 256) are currently
used. This is due to address ranges defined for special device families.
Master redundancy
Some BMS devices such as FTC470XDP, FTC470XMB, FTC470XET
and MK2430 are capable of acting as redundant Master. In the event
of failure of the regular master (bus address 1) after approximately
60 seconds such a device takes over the Master function in order
to control the BMS bus. If the regular master becomes active again,
the FTC470 returns the temporary master function.
Interrogation of all connected devices (internal BMS bus)
During normal operation, the master transmits a request to every
device within the address range for the number of alarm messages.
If alarm messages are present, all channels of the respective device
are requested. Then the address ranges are requested for the number
of operating messages and if messages exist, the channels of the
respective devices are requested too. In addition, every other second
all slaves are requested for possible interruptions via the broadcast
address 0. That ensures that new alarm messages are available on
the bus within two seconds at the latest.

3 4
1
2
BMS bus structure
1, 5 - The first and last bus node always requires a terminating
resistor of 120 Ω.
2 - Connect the bus cable on one side to earth J-Y(St)Y 2 x 0.6.
Make sure that the shield is properly connected after separating
the cable.
3 - Only one master may exist on each BMS bus (setting via menu).
4, 6 - Address setting should be sequentially 1, 2, 3 … “without gaps”.
6 - Maximum number of addresses respectively nodes 32
(repeater DI-1PSM not included).
7 - If the cable length exceeds 1200 m, a DI-1PSM repeater must
be used.
8 - LAN cable between FTC470XET and the personal computer:
a standard cable in case of direct connection, a cross over
cable in case of router connection.
2. PROFIBUS
PROFIBUS is a fast, open bus system widely known in the field of
automation. It is internationally standardised (IEC 61158 and
EN50170) and is available in three variants:
• PROFIBUS FMS (Fieldbus Message Specification)
• PROFIBUS PA (Process Automation)
• PROFIBUS DP (Decentral Periphery)
The protocol converter FTC470XDP supports the PROFIBUS DP.
Here, central control devices (e.g. programmable controllers) com-
municate with decentralised input and output modules via a fast serial
connection. BMS bus devices are connected with the PROFIBUS DP
via the FTC470XDP. For control purposes, a PROFIBUS MASTER is
required.
3. Jbus/Modbus
Jbus/Modbus is an open, serial communication protocol based on
the Master/Slave principle. Easy to be implemented to any serial
interface, it has become very popular. The Modbus protocol initially
has been developed for networking control systems but is now
often used for the connection of input and output modules. Owing
to the low transmission rate of maximum 57.6 kbaud, the Modbus
is specifically designed for systems with limited bus nodes or for time-
critical applications. The protocol converter FTC470XMB is designed
for the connection of BMS devices to Modbus RTU. A Modbus
master is required for the control of an FTC470XMB.
The technical aspects when using Bender communication solutions
6
7
8
5
1 5
Hardware characteristics
• Connection half duplex
• Communication master/slave
• Nodes < 32
• Cable length < 1200 m
• Recommended cable (shielded, shield on one side connected to PE)
J-Y(St)Y 2 x 0.6
• Terminating resistor 120 Ω (0.25 W)
Technical data – BMS bus
• Interface parameters
• Transmission 1 start bit, 7 data bits, 1 parity bit, 1 stop bit
• Baud rate 9600 baud
• Parity even
• Checksum/sum of all bytes transmitted 0 (without CR and LF)
• Data transmission with ASCII characters, yet not all characters
are permitted.
4. Ethernet/TCP/IP
The Ethernet is a widely used vendor-independent technology
enabling data transfer of 10, 100 or 1000 millions bits per second
(Mbps) in the Lokal Area Network (LAN). The Ethernet belongs to
the classic systems among the bus systems and has established
itself as a standard in the IT world. With the FTC470XET protocol
converter, Bender provides the solution for this application. A
complete web server integrated in the protocol converter allows
easy operation and control of Bender systems by means of a standard
browser via any personal computer. The integrated OPC server allows
data to be transferred to building management systems or to visua-
lisation software.
5. OPC
The OPC (OLE for Process Control) is a standardised software tech-
nology. OPC is a standardized software in the field of automation
technology and is based on Microsoft COM and DCOM technology.
It allows different programs of different manufacturers to commu-
nicate with each other. OPC is not a protocol, but a client/server
application. It does not replace field buses. The OPC makes data
available which can be accessed by OPC clients. The OPC server of
the FTC470XET and the Bender OPC server supports the specification
DA (Data Access) 1.0 and 2.0.
Two OPC servers are available
• Integrated in the protocol converter /web server FTC470XET
• Software solution for personal computers as BMS OPC server
Technical aspects – Main catalogue Part 1 35
 Right to modifications reserved! – Technical aspects / HKT1de / 04.2009 / 2500 / Schw / JD-Druck / © Dipl.-Ing. W. Bender GmbH & Co. KG, Germany

Dipl.-Ing. W. Bender GmbH & Co KG

P.O. Box 1161 • 35301 Grünberg • Germany
Londorfer Straße 65 • 35305 Grünberg • Germany
Tel.: +49 6401 807-0 • Fax: 06401 807-259
E-Mail: info@bender-de.com • www.bender-de.com

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